US20110218301A1 - Polymer and method for producing the same - Google Patents

Polymer and method for producing the same Download PDF

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US20110218301A1
US20110218301A1 US13/042,827 US201113042827A US2011218301A1 US 20110218301 A1 US20110218301 A1 US 20110218301A1 US 201113042827 A US201113042827 A US 201113042827A US 2011218301 A1 US2011218301 A1 US 2011218301A1
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polymer
ring
molecular weight
surfactant
cyclic
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Inventor
Taichi NEMOTO
Nobuyuki Mase
Takeshi Sako
Idzumi Okajima
Shunsuke Mori
Chiaki Tanaka
Yoshitaka Yamauchi
Jyun Ishiduka
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Ricoh Co Ltd
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Shizuoka University NUC
Ricoh Co Ltd
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Priority claimed from JP2010173296A external-priority patent/JP5668354B2/ja
Priority claimed from JP2010176518A external-priority patent/JP5609399B2/ja
Application filed by Shizuoka University NUC, Ricoh Co Ltd filed Critical Shizuoka University NUC
Assigned to RICOH COMPANY, LTD., NATIONAL UNIVERSITY CORPORATION SHIZUOKA UNIVERSITY reassignment RICOH COMPANY, LTD. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: MORI, SHUNSUKE, Ishiduka, Jyun, MASE, NOBUYUKI, SAKO, TAKESHI, OKAJIMA, IDZUMI, TANAKA, CHIAKI, Nemoto, Taichi, YAMAUCHI, YOSHITAKA
Publication of US20110218301A1 publication Critical patent/US20110218301A1/en
Assigned to RICOH COMPANY, LTD. reassignment RICOH COMPANY, LTD. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: NATIONAL UNIVERSITY CORPORATION SHIZUOKA UNIVERSITY
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    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G63/00—Macromolecular compounds obtained by reactions forming a carboxylic ester link in the main chain of the macromolecule
    • C08G63/78—Preparation processes
    • C08G63/82—Preparation processes characterised by the catalyst used
    • C08G63/823—Preparation processes characterised by the catalyst used for the preparation of polylactones or polylactides
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G63/00—Macromolecular compounds obtained by reactions forming a carboxylic ester link in the main chain of the macromolecule
    • C08G63/02—Polyesters derived from hydroxycarboxylic acids or from polycarboxylic acids and polyhydroxy compounds
    • C08G63/06—Polyesters derived from hydroxycarboxylic acids or from polycarboxylic acids and polyhydroxy compounds derived from hydroxycarboxylic acids
    • C08G63/08—Lactones or lactides
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G63/00—Macromolecular compounds obtained by reactions forming a carboxylic ester link in the main chain of the macromolecule
    • C08G63/78—Preparation processes
    • C08G63/81—Preparation processes using solvents
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G64/00—Macromolecular compounds obtained by reactions forming a carbonic ester link in the main chain of the macromolecule
    • C08G64/02—Aliphatic polycarbonates
    • C08G64/0208—Aliphatic polycarbonates saturated
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G64/00—Macromolecular compounds obtained by reactions forming a carbonic ester link in the main chain of the macromolecule
    • C08G64/20—General preparatory processes
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G64/00—Macromolecular compounds obtained by reactions forming a carbonic ester link in the main chain of the macromolecule
    • C08G64/20—General preparatory processes
    • C08G64/38—General preparatory processes using other monomers

Definitions

  • the present invention relates to a method for producing a polymer in a compressive fluid through polymerization of a ring-opening polymerizable monomer in the presence of an organic catalyst, and to a polymer obtained by this method.
  • Plastics derived from petroleum have been mass-produced to support our lives in various ways, since most of them are light, tough, excellent in durability, and can easily be molded into a desired shape. However, when released to the environment, these plastics accumulate without being readily degraded. Also, they emit a large amount of carbon dioxide during combustion, accelerating progress of global warming.
  • polylactic acid is a plastic made of lactic acid or its lactide (cyclic diester) obtainable from natural products, and also excellent in heat resistance and well-balanced between color and mechanical strength.
  • a lactide which is a starting material for polylactic acid.
  • Production of polylactic acid using a lactide as a starting material is generally performed as follows. Specifically, a metal catalyst (e.g., tin octylate) is added to a lactide of L- or D-lactic acids, followed by melt polymerization at about 200° C. under atmospheric or reduced pressure in an inert gas atmosphere. This method can produce poly-L-lactic acid or poly-D-lactic acid having a relatively high molecular weight.
  • a metal catalyst e.g., tin octylate
  • the metal catalyst however, remains in the resultant polylactic acid without being subjected to treatments such as washing with an acid and metal removal.
  • the remaining metal catalyst degrades heat resistance and safety of the polylactic acid.
  • the polymerization at high temperatures requires a large amount of energy, which is problematic.
  • the polylactic acid and the lactide exist in equilibrium, and thus, the melt polymerization at about 200° C. cannot produce polylactic acid without containing the residual lactide.
  • the lactide contained in the resultant polylactic acid and impurities such as decomposed matters of the polylactic acid cause generation of foreign matters during molding and degrade physical properties of the polylactic acid (glass transition temperature and melt viscosity), considerably deteriorating moldability and thermal stability thereof.
  • the lactide contained in the polylactic acid is removed in vacuum, or re-precipitation, extraction in hot water, and other treatments are performed (see Japanese Patent Application Laid-Open (JP-A) No. 2008-63420).
  • JP-A No. 2009-1619 discloses a method in which ring-opening polymerization of lactides is performed in methylene chloride (solvent) with an organic catalyst. This method can produce polylactic acid at high yield.
  • Emulsion polymerization, dispersion polymerization or suspension polymerization of a vinyl monomer is exemplified as a method for producing fine polymer particles from a monomer in supercritical carbon dioxide.
  • Polymerization and particle formation in supercritical carbon dioxide have the following advantages over polymerization in organic solvents, and thus are utilized as a method for producing fine polymer particles from various monomers.
  • the obtained polymer particles are used for various applications such as electrophotographic developers, printing inks, building paints and cosmetics. Specifically, the advantages are as follows.
  • Solvent removal and drying after polymerization can be simplified since a dry polymer can be obtained at one step.
  • Treatment of waste solvent can be omitted since no waste liquid is formed.
  • Highly toxic organic solvent is not needed.
  • Residual unreacted monomer components and hazardous materials can be removed at a washing step.
  • Used carbon dioxide can be recovered and recycled.
  • JP-A No. 2009-167409 discloses a method of synthesizing colored polymer particles from a radical polymerizable monomer in the presence of a surfactant containing a perfluoroalkyl group.
  • the fluorine-containing surfactant used in this method is very expensive and also is problematic in terms of safety. Further, this method problematically cannot produce polymer particles having a small molecular weight distribution (Mw/Mn) (about 2 or smaller) attained by the present invention.
  • JP-A No. 2009-132878 discloses a method of producing polymer particles using a polymer radical polymerization initiator containing an organosiloxane skeleton, while synthesizing a polymer surfactant at one step without separately synthesizing and preparing surfactants suitable for monomers.
  • an object of the present invention is to provide a method for efficiently producing a polymer from a ring-opening polymerizable monomer at high yield through one step with less residual monomers, wherein the polymer has a molecular weight controlled as desired and a narrow molecular weight distribution. This method requires no metal catalyst and no additional step of removing the residual monomer or other unnecessary materials.
  • Another object of the present invention is to provide a polymer obtained by this method.
  • a method for producing a polymer including:
  • ⁇ 2> The method according to ⁇ 1>, wherein the polymerizing the ring-opening polymerizable monomer is performed in the presence of a surfactant to produce the polymer in a form of particles.
  • ⁇ 4> The method according to ⁇ 2> or ⁇ 3>, wherein the surfactant has a perfluoroalkyl group, a polydimethylsiloxane group or a polyacrylate group.
  • ⁇ 5> The method according to any one of ⁇ 1> to ⁇ 4>, wherein a polymer conversion rate of the ring-opening polymerizable monomer is 95 mol % or higher.
  • ⁇ 6> The method according to any one of ⁇ 1> to ⁇ 5>, wherein the organic catalyst is a nucleophilic nitrogen compound having basicity.
  • ⁇ 8> The method according to any one of ⁇ 1> to ⁇ 7>, wherein the organic catalyst is any one selected from the group consisting of a cyclic amine, a cyclic diamine, a cyclic diamine compound having an amidine skeleton, a cyclic triamine compound having a guanidine skeleton, a heterocyclic aromatic organic compound containing a nitrogen atom and an N-heterocyclic carbene.
  • the organic catalyst is any one selected from the group consisting of a cyclic amine, a cyclic diamine, a cyclic diamine compound having an amidine skeleton, a cyclic triamine compound having a guanidine skeleton, a heterocyclic aromatic organic compound containing a nitrogen atom and an N-heterocyclic carbene.
  • the organic catalyst is any one selected from the group consisting of 1,4-diazabicyclo-[2.2.2]octane, 1,8-diazabicyclo[5.4.0]undec-7-ene, 1,5,7-triazabicyclo[4.4.0]dec-5-ene, diphenylguanidine, N,N-dimethyl-4-aminopyridine, 4-pyrrolidinopyridine and 1,3-di-tert-butylimidazol-2-ylidene.
  • ring-opening polymerizable monomer is a monomer having an ester bond in a ring thereof.
  • cyclic ester is a cyclic dimer obtained by dehydration-condensating L-form compounds with each other, D-form compounds with each other, or an L-form compound with a D-form compound, each of the compounds being represented by General Formula a:
  • R represents a C1-C10 alkyl group.
  • ring-opening polymerizable monomer is a lactide of L-form lactic acids, a lactide of D-form lactic acids, or a lactide of an L-form lactic acid and a D-form lactic acid.
  • ⁇ 14> The method according to any one of ⁇ 1> to ⁇ 13>, wherein the compressive fluid is formed of carbon dioxide.
  • ⁇ 15> The method according to any one of ⁇ 1> to ⁇ 14>, wherein the polymer has a molecular weight distribution Mw/Mn of 1.5 or less, where Mw denotes a weight average molecular weight of the polymer and Mn denotes a number average molecular weight of the polymer.
  • ⁇ 16> The method according to any one of ⁇ 1> to ⁇ 15>, wherein the polymer contains a urethane bond or an ether bond in a molecule thereof.
  • ⁇ 17> A polymer obtained by the method according to any one of ⁇ 1> to ⁇ 16>.
  • the present invention can provide a method for efficiently producing a polymer from a ring-opening polymerizable monomer at high yield through one step with less residual monomers, wherein the polymer has a molecular weight controlled as desired and a narrow molecular weight distribution, and the method requires no metal catalyst, which considerably degrades thermal stability and safety of the resultant polymer, and requires no additional step of removing the residual monomer or other unnecessary materials, which step considerably degrades moldability and thermal stability of the resultant polymer; and a polymer obtained by this method.
  • FIG. 1 is a general phase diagram showing the state of a substance varying depending on pressure and temperature conditions.
  • FIG. 2 is a phase diagram which defines a compressive fluid used in the present invention.
  • FIG. 3 is an electron microscope image showing the aggregation state of polymer particles 1.
  • FIG. 4 is an electron microscope image of each of polymer particles 1.
  • FIG. 5 is an image obtained by photographing polymer particles 1 with a digital camera.
  • FIG. 6 is an image obtained by photographing an aggregated polymer of Comparative Example 2-1 with a digital camera.
  • the present invention has technical features of polymerizing a ring-opening polymerizable monomer in a compressive fluid and of using an organic catalyst containing no metal atom (metal-free organic catalyst).
  • supercritical carbon dioxide is considered unusable as a solvent for living anionic polymerization, since carbon dioxide is reactive with a nucleophilic compound having basicity (see “The Latest Applied Technology of Supercritical Fluid (CHO RINKAI RYUTAI NO SAISHIN OUYOU GIJUTSU,” p. 173, published by NTS Inc. on Mar. 15, 2004).
  • the present invention has overcome this conventional finding. That is, it has been found that a nucleophilic organic catalyst having basicity stably coordinates with a ring-opening polymerizable monomer to open the ring thereof, and the polymerization reaction quantitatively proceeds and as a result proceeds in a living manner even in supercritical carbon dioxide.
  • a reaction proceeds in a living manner means that the reaction quantitatively proceeds without involving side reactions such as migration reaction and termination reaction, and the produced polymer has a narrow molecular weight distribution (monodispersity).
  • the method of the present invention employs a metal-free organic catalyst and thus, can solve the above-described various problems.
  • the present invention has a technical feature of polymerizing a ring-opening polymerizable monomer simultaneously with granulating the resultant polymer (particle formation) in a compressive fluid in the presence of a surfactant additionally added.
  • the present invention first discloses the granulation of polymers using the ring-opening polymerizable monomer in the compressive fluid.
  • the “compressive fluid” refers to a substance present in any one of the regions (1), (2) and (3) of FIG. 2 in the phase diagram of FIG. 1 .
  • Pc and Tc denote a critical pressure and a critical temperature, respectively.
  • the substance present in the region (1) is a supercritical fluid.
  • the supercritical fluid is a fluid that exists as a noncondensable high-density fluid at a temperature and a pressure exceeding the corresponding critical points, which are limiting points at which a gas and a liquid can coexist.
  • the supercritical fluid does not condense even when compressed, and exists at a critical temperature or higher and a critical pressure or higher.
  • the substance present in the region (2) is a liquid, but in the present invention, is a liquefied gas obtained by compressing a substance existing as a gas at normal temperature (25° C.) and normal pressure (1 atm).
  • the substance present in the region (3) is a gas, but in the present invention, is a high-pressure gas whose pressure is 1 ⁇ 2 Pc or higher.
  • the substance usable as the compressive fluid examples include carbon monoxide, carbon dioxide, dinitrogen monoxide, nitrogen, methane, ethane, propane, 2,3-dimethylbutane and ethylene. These may be used alone or in combination.
  • carbon dioxide is preferred, since its critical pressure and temperature are about 7.4 MPa and about 31° C., it can be easily brought into a critical state, and it is nonflammable to allow easy handling.
  • the temperature is preferably 25° C. or higher and the pressure is preferably 5 MPa or higher, considering the reaction efficiency, etc. More preferably, supercritical carbon dioxide is used.
  • the pressure upon polymerization i.e., the pressure of the compressive fluid
  • the pressure upon polymerization is preferably a pressure at which the compressive fluid is brought into a supercritical state, in order to increase dissolvability of the monomer into the compressive fluid and make the polymerization reaction to proceed uniformly and quantitatively, although the compressive fluid may be high-pressure gas or liquefied gas.
  • the pressure must be 3.7 MPa or higher, preferably 5 MPa or higher, more preferably 7.4 MPa (critical pressure) or higher.
  • the ring-opening polymerizable monomer which can be polymerized in the present invention preferably contains an ester bond in the ring.
  • Examples thereof include cyclic esters and cyclic carbonates.
  • cyclic esters are not particularly limited and may be those known in the art.
  • Particularly preferred monomers are, for example, cyclic dimers obtained by dehydration-condensating L-form compounds with each other, D-form compounds with each other, or an L-form compound with a D-form compound, each of the compounds being represented by General Formula a: R—C*—H(—OH)(COOH) where R represents a C1-C10 alkyl group.
  • Specific examples of the compound represented by General Formula a include enantiomers of lactic acid, enantiomers of 2-hydroxybutanoic acid, enantiomers of 2-hydroxypentanoic acid, enantiomers of 2-hydroxyhexanoic acid, enantiomers of 2-hydroxyheptanoic acid, enantiomers of 2-hydroxyoctanoic acid, enantiomers of 2-hydroxynonanoic acid, enantiomers of 2-hydroxydecanoic acid, enantiomers of 2-hydroxyundecanoic acid, and enantiomers of 2-hydroxydodecanoic acid.
  • enantiomers of lactic acid are particularly preferred since they have high reactivity and are easily available.
  • the cyclic dimers may be used alone or in combination.
  • the other cyclic esters than those represented by General Formula a include aliphatic lactones such as ⁇ -propiolactone, ⁇ -butyrolactone, ⁇ -butyrolactone, ⁇ -hexanolactone, ⁇ -octanolactone, ⁇ -valerolactone, ⁇ -hexanolactone, ⁇ -octanolactone, ⁇ -caprolactone, ⁇ -dodecanolactone, ⁇ -methyl- ⁇ -butyrolactone, ⁇ -methyl- ⁇ -valerolactone, glycolide and lactide.
  • E-caprolactone is particularly preferred since it has high reactivity and is easily available.
  • non-limiting examples of the cyclic carbonates include ethylene carbonate and propylene carbonate.
  • the ring-opening polymerizable monomers may be used alone or in combination.
  • the obtained polymer preferably has a glass transition temperature equal to or higher than room temperature. When the glass transition temperature is too low, the polymer cannot be recovered as particles in some cases.
  • the organic catalyst employed in the method of the present invention for producing a polymer is preferably a metal-free organic catalyst in consideration of the influences to the environment.
  • the metal-free organic catalyst may be any catalysts so long as they act on ring-opening reaction of the ring-opening polymerizable monomer to form an active intermediate together with the ring-opening polymerizable monomer and then are removed (regenerated) through reaction with an alcohol.
  • the polymerization reaction proceeds even using a cationic catalyst.
  • the cationic catalyst pulls hydrogen atoms out from the polymer backbone (back-biting).
  • back-biting back-biting
  • the produced polymer has a broad molecular weight distribution and also, high-molecular-weight polymers are difficult to obtain.
  • preferred are compounds having basicity and serving as a nucleophilic agent.
  • the compounds include cyclic monoamines, cyclic diamines (cyclic diamine compounds having an amidine skeleton), cyclic triamine compounds having a guanidine skeleton, heterocyclic aromatic organic compounds containing a nitrogen atom and N-heterocyclic carbenes.
  • Non-limiting examples of the cyclic amine include quinuclidine.
  • Non-limiting examples of the cyclic diamine include 1,4-diazabicyclo-[2.2.2]octane (DAB CO) and 1,5-diazabicyclo(4,3,0)nonene-5.
  • Non-limiting examples of the cyclic diamine compound having an amidine skeleton include 1,8-diazabicyclo[5.4.0]undec-7-ene (DBU) and diazabicyclononene.
  • Non-limiting examples of the cyclic triamine compound having a guanidine skeleton include 1,5,7-triazabicyclo[4.4.0]dec-5-ene (TBD) and diphenylguanidine (DPG).
  • Non-limiting examples of the heterocyclic aromatic organic compound containing a nitrogen atom include N,N-dimethyl-4-aminopyridine (DMAP), 4-pyrrolidinopyridine (PPY), pyrrocolin, imidazole, pyrimidine and purine.
  • Non-limiting examples of the N-heterocyclic carbene include 1,3-di-tert-butylimidazol-2-ylidene (ITBU). Of these, DABCO, DBU, DPG, TBD, DMAP, PPY and ITBU are preferred.
  • the amount of the organic catalyst is preferably 0.01 mol % to 15 mol %, more preferably 0.1 mol % to 1 mol %, still more preferably 0.3 mol % to 0.5 mol %, relative to 100 mol % of the ring-opening polymerizable monomer.
  • the amount of the organic catalyst used is less than 0.01 mol %, the organic catalyst is deactivated before completion of the polymerization reaction, and as a result a polymer having a target molecular weight cannot be obtained in some cases.
  • the amount of the organic catalyst used is more than 15 mol %, it may be difficult to control the polymerization reaction.
  • the polymerization reaction temperature cannot flatly be determined since it varies depending on, for example, combinations of the compressive fluid, the ring-opening polymerizable monomer and the organic catalyst.
  • the polymerization reaction temperature is about 40° C. to about 150° C., preferably 50° C. to 120° C., more preferably 60° C. to 100° C.
  • the reaction rate easily decreases, and as a result the polymerization reaction cannot be made to proceed quantitatively in some cases.
  • the polymerization reaction temperature exceeds 150° C., depolymerization reaction proceeds in parallel, and as a result the polymerization reaction cannot be made to proceed quantitatively.
  • the polymerization reaction time is appropriately determined considering the target molecular weight of the polymer.
  • the polymerization reaction time is generally 2 hours to 12 hours.
  • the difference in density between the monomers and the polymer particles is compensated through stirring so that the polymer particles do not sediment.
  • the pressure upon polymerization i.e., the pressure of the compressive fluid
  • the pressure upon polymerization is preferably a pressure at which the compressive fluid is brought into a supercritical state in order to increase dissolvability of the monomer into the compressive fluid and make the polymerization reaction to proceed uniformly and quantitatively, although the compressive fluid may be high-pressure gas or liquefied gas.
  • the pressure is 3.7 MPa or higher, preferably 7.4 MPa or higher.
  • a ring-opening polymerization initiator is preferably added to the reaction system in order to control the molecular weight of the obtained polymer.
  • the ring-opening polymerization initiator may be those known in the art such as alcohols.
  • the alcohols may be, for example, any of saturated or unsaturated, aliphatic mono-, di- or polyalcohols.
  • monoalcohols such as methanol, ethanol, propanol, butanol, pentanol, hexanol, heptanol, nonanol, decanol, lauryl alcohol, myristyl alcohol, cetyl alcohol and stearyl alcohol; dialcohols such as ethylene glycol, 1,2-propanediol, 1,3-propanediol, 1,3-butanediol, 1,4-butanediol, hexanediol, nonanediol, tetramethylene glycol and polyethylene glycol; polyalcohols such as glycerol, sorbitol, xylitol, ribitol, erythritol and triethanolamine; and methyl lactate and ethyl lactate. Also, use of a polymer containing an alcohol residue at the end enables synthesis of diblock copolymers and triblock
  • the amount of the ring-opening polymerization initiator used may be appropriately adjusted considering the target molecular weight of the polymer.
  • the amount of the ring-opening polymerization initiator is about 0.1 parts by mass to about 5 parts by mass relative to 100 parts by mass of the ring-opening polymerizable monomer.
  • a polymerization terminator e.g., benzoic acid, hydrochloric acid, phosphoric acid, metaphosphoric acid, acetic acid and lactic acid
  • a polymerization terminator e.g., benzoic acid, hydrochloric acid, phosphoric acid, metaphosphoric acid, acetic acid and lactic acid
  • the polymerization system may further contain a surfactant that dissolves in the compressive fluid and has compatibility to both the compressive fluid and the ring-opening polymerizable monomer.
  • a surfactant that dissolves in the compressive fluid and has compatibility to both the compressive fluid and the ring-opening polymerizable monomer.
  • Making the polymerization reaction to proceed uniformly using the surfactant has such advantageous effects that, for example, the resultant polymer can have a narrow molecular weight distribution and easily produced as particles.
  • the surfactant having a CO 2 -philic group and a monomer-philic group in the molecule may be used.
  • CO 2 -philic group examples include a perfluoroalkyl group, a polyacrylate group, a polydimethylsiloxane group, an ether group and a carbonyl group.
  • a compound containing an active hydrogen in its structure e.g., an alcohol
  • the surfactant is preferably used as the surfactant, since such a compound can serve as not only the surfactant but also the initiator.
  • the monomer-philic group may be selected in consideration of the type of the monomer used.
  • the monomer used is a lactide or lactone
  • the surfactant When the surfactant is incorporated into the polymerization system, the surfactant may be added to the compressive fluid or the ring-opening polymerizable monomer.
  • surfactant examples include those containing, as a partial structure, a structure represented by any one of General Formulas (1) to (7):
  • R1 to R5 each represent a hydrogen atom or a C1-C4 lower alkyl group
  • R6 to R8 represent a C1-C4 lower alkyl group
  • R1 to R8 may be identical or different
  • R9 represents a hydrogen atom or a methyl group
  • R10 represents a methylene group or an ethylene group
  • Rf represents a C7-C10 perfluoroalkyl group and q is an integer of 1 or greater indicating the number of repeating units; and also, the molecular weight of the surfactant is 2,500 or lower
  • R9 represents a hydrogen atom or a methyl group and each of r and p is an integer of 1 or greater indicating the number of repeating units; and also, the molecular weight of the surfactant is 5,500 or lower,
  • R6 to R8 each represent a C1-C4 lower alkyl group
  • R represents a C1-C4 lower alkylene group
  • R6 to R8 may be identical or different
  • n is an integer of 1 or greater indicating the number of repeating units and Me denotes a methyl group; and the molecular weight of the surfactant is 5,000 or lower,
  • R9 represents a C1-C4 lower alkyl group
  • X represents a hydrophilic group (e.g., a hydroxy group, a carboxyl group and an amino group)
  • R10 represents a C1-C4 lower alkyl group
  • Y represents an oxygen atom or a sulfur atom
  • Ph denotes a phenyl group
  • surfactants containing a partial structure represented by General Formula (1) in which R6 to R8 each preferably represent a methyl group and k is preferably 2.
  • the surfactant containing the partial structure represented by General Formula (1) is particularly preferably surfactant 1 given below.
  • This surfactant is commercially available from Croda Japan under the trade name of “MONASIL PCA.”
  • each of m and n is an integer of 1 or greater indicating the number of repeating units.
  • the surfactant used in the present invention may be other surfactants than those represented by General Formulas (1) to (7), so long as they dissolve in the compressive fluid and have compatibility to both the compressive fluid and the ring-opening polymerizable monomer.
  • Examples of the other surfactants include those represented by the following General Formulas (8) to (11), where each of m and n is an integer of 1 or greater indicating the number of repeating units.
  • the surfactant to be used is appropriately selected depending on the type of the compressive fluid or considering whether the target product is polymer particles and seed particles (described below) or growth particles. From the viewpoint of sterically and electrostatically preventing the resultant polymer particles from being aggregated, particularly preferred are surfactants that have high compatibility and adsorbability to the surfaces of the polymer particles and also have high compatibility and dissolvability to the compressive fluid. Of these surfactants, particularly preferred are those having a block structure of hydrophilic groups and hydrophobic groups, since they have an excellent granularity.
  • the surfactants selected have a molecular chain of a certain length, preferably have a molecular weight of 10,000 or higher.
  • the molecular weight is too large, the surfactant is considerably increased in liquid viscosity, causing poor operability and poor stirring performance.
  • a large amount of the surfactant may be deposited on the surfaces of some particles while a small amount of the surfactant may be deposited on the surfaces of other particles.
  • the amount of the surfactant used varies depending on the type of the ring-opening polymerizable monomer or the surfactant. In general, it is preferably 0.1% by mass to 10% by mass, more preferably 1% by mass to 5% by mass, relative to the amount of the compressive fluid.
  • the concentration of the surfactant in the compressive fluid When the concentration of the surfactant in the compressive fluid is low, the produced polymer particles have a relatively large particle diameter. When the concentration of the surfactant in the compressive fluid is high, the produced polymer particles have a small particle diameter. However, even when used in an amount exceeding 10% by mass, the surfactant does not contribute to the production of the polymer particles having a small particle diameter.
  • the particles produced at an early stage of polymerization are stabilized by the surfactant existing in equilibrium between the compressive fluid and the surfaces of the polymer particles.
  • the concentration of the polymer particles becomes high, resulting in that the polymer particles disadvantageously aggregate regardless of steric repulsion caused by the surfactant.
  • the amount of the ring-opening polymerizable monomer is extremely larger than that of the compressive fluid, the produced polymer is totally dissolved, resulting in that the polymer is precipitated only after the polymerization proceeds to some extent.
  • the precipitated polymer particles are in the form of highly adhesive aggregated matter.
  • the amount of the ring-opening polymerizable monomer used for producing polymer particles relative to the compressive fluid.
  • the amount thereof is preferably 500% by mass or less, more preferably 250% by mass or less, relative to the amount of the compressive fluid.
  • the density of the ring-opening polymerizable monomer varies depending on the state of the compressive fluid, the amount of the ring-opening polymerizable monomer also varies depending on the state of the compressive fluid.
  • the state of the polymer can be observed with, for example, a scanning electron microscope or SEM.
  • the production method of the present invention can produce polymer particles having an average particle diameter of 1 mm or less.
  • the particle diameter can be controlled by controlling, for example, the pressure, temperature and reaction time during the reaction, and the amount of the surfactant used. If necessary, by varying the reaction conditions, various polymer particles from truly spherical polymer particles to amorphous polymer particles can be obtained.
  • the polymerization method employable in the present invention is, for example, dispersion polymerization, suspension polymerization and emulsion polymerization, and may be selected from these methods depending on the intended purpose.
  • dispersion polymerization is superior to suspension polymerization or emulsion polymerization, since it can make the most of the advantages of the compressive fluid, monodispersed polymer particles can be obtained, and the produced polymer particles have a narrow particle size distribution.
  • polymer particles seed particles having a smaller particle diameter than the target particle diameter and a narrow particle size distribution, are added in advance and grown through reaction with the monomer in the same system as described above.
  • the monomer used in the growth reaction may be the same as or different from that used for producing the seed particles.
  • the produced polymer must be dissolved in the compressive fluid.
  • a polymerization initiator may be employed.
  • the polymerization initiator include aliphatic monoalcohols and polyalcohols.
  • Examples of the aliphatic monoalcohol include methanol, ethanol, propanol, isopropanol, butanol, hexanol and pentanol.
  • Examples of the aliphatic polyalcohol include ethylene glycol, propylene glycol, 1,3-butanediol, 1,4-butanediol, 2,3-butanediol, diethylene glycol, triethylene glycol, 1,5-pentanediol, 1,6-hexanediol, neopentyl glycol, 2-ethyl-1,3-hexanediol, polyethylene glycol, triethanol amine, hydrogenated bisphenol A, and divalent alcohols obtained by adding to bisphenol A a cyclic ether such as ethylene oxide or propylene oxide.
  • a cyclic ether such as ethylene oxide or propylene oxide.
  • One exemplary process of the polymerization is as follows. Specifically, a surfactant is completely dissolved in a compressive fluid; one or more ring-opening polymerizable monomers and a polymerization initiator are added to the compressive fluid; and the resultant mixture is heated to a temperature corresponding to the decomposition rate of the polymerization initiator while stirred at a rate at which the flow of the reaction container becomes uniform.
  • the heating temperature is preferably 40° C. to 100° C., more preferably 50° C. to 85° C.
  • the temperature at an early stage of the polymerization greatly influences the particle diameter of the produced polymer particles.
  • the temperature of the resultant mixture is increased to the polymerization temperature, and then the initiator is dissolved in a small amount of the compressive fluid and added to the mixture.
  • the reaction container Upon polymerization, the reaction container must be purged with an inert gas (e.g., nitrogen gas, argon gas or carbon dioxide gas) to sufficiently remove water contained in the air of the reaction container.
  • an inert gas e.g., nitrogen gas, argon gas or carbon dioxide gas
  • the water content of the polymerization reaction system is 4 mol % or less relative to 100 mol % of the ring-opening polymerizable monomer.
  • water content is preferably 1 mol % or less, more preferably 0.5 mol %. If necessary, such a pre-treatment may be performed that removes water contained in the ring-opening polymerizable monomer and the other raw materials.
  • the polymerization speed can be increased by terminating the polymerization when the desired particle diameter and particle size distribution are attained, by gradually adding the polymerization initiator, or by performing the reaction under high-pressure conditions.
  • the conversion rate of monomer to polymer is not particularly limited and may be selected depending on the intended purpose.
  • the conversion rate is preferably 95 mol % or higher.
  • the amount of unreacted monomer is calculated from the following equation: 100 ⁇ the ratio of a peak area attributed to the unreacted monomer to a peak area attributed to the reacted polymer.
  • a polymer of the present invention is a polymer obtained by the method of the present invention for producing a polymer.
  • the molecular weight distribution (weight average molecular weight or Mw/number average molecular weight or Mn) of the polymer is not particularly limited and may be appropriately selected depending on the intended purpose.
  • the molecular weight distribution is preferably 2 or less, more preferably 1.5 or less.
  • the molecular weight of the polymer can be measured through, for example, gel permeation chromatography or GPC.
  • the polymer of the present invention can be suitably used for various applications such as biodegradable resins, electrophotographic developers, printing inks, building paints and cosmetics.
  • the molecular weight and the polymer conversion rate were measured as follows.
  • the molecular weight was measured through gel permeation chromatography or GPC under the following conditions.
  • GPC-8020 (product of TOSOH CORPORATION)
  • a calibration curve of molecular weight was obtained using monodispersed polystyrene serving as a standard sample.
  • a polymer sample (1 mL) having a polymer concentration of 0.5% by mass was applied and measured under the above conditions, to thereby obtain the molecular weight distribution of the polymer.
  • the number average molecular weight Mn and the weight average molecular weight Mw of the polymer were calculated from the calibration curve.
  • the molecular weight distribution is a value calculated by dividing Mw with Mn.
  • the conversion rate of monomer to polymer was calculated in the below-described manner from Equation 1.
  • the amount of unreacted monomer was calculated in deuterated chloroform with a nuclear magnetic resonance apparatus JNM-AL300 (product of JEOL Ltd.) as a value obtained as follows: 100 ⁇ the ratio of a quartet peak area attributed to lactide (4.98 ppm to 5.05 ppm) to a quartet peak area attributed to polylactic acid (5.10 ppm to 5.20 ppm).
  • the amount of unreacted monomer (mol %) was calculated in deuterated chloroform with a nuclear magnetic resonance apparatus JNM-AL300 (product of JEOL Ltd.) as a value obtained as follows: 100 ⁇ the ratio of a triplet peak area attributed to caprolactone (4.22 ppm to 4.25 ppm) to a triplet peak area attributed to polycaprolactone (4.04 ppm to 4.08 ppm).
  • the amount of unreacted monomer (mol %) was calculated in deuterated chloroform with a nuclear magnetic resonance apparatus JNM-AL300 (product of JEOL Ltd.) as a value obtained as follows: 100 ⁇ the ratio of a singlet peak area attributed to ethylene carbonate (4.54 ppm) to a quartet peak area attributed to polycarbonate (4.22 ppm to 4.25 ppm).
  • a pressure-resistant container was charged with a lactide of an L-lactic acid (90 parts by mass), a lactide of a D-lactic acid (10 parts by mass), lauryl alcohol (serving as an initiator) in an amount of 3.00 mol % relative to 100 mol % of the monomer, and 4-pyrrolidinopyridine (PPY) (3.3 parts by mass) and then heated to 60° C.
  • a lactide of an L-lactic acid 90 parts by mass
  • a lactide of a D-lactic acid 10 parts by mass
  • lauryl alcohol serving as an initiator
  • PPY 4-pyrrolidinopyridine
  • a pressure pump and a back pressure valve were used to adjust the flow rate at the outlet of the back pressure valve to 5.0 L/min. Then, supercritical carbon dioxide was allowed to flow for 30 min, and PPY and the residual monomer (lactide) were removed.
  • reaction system was gradually returned to normal temperature and normal pressure. Three hours after, a polymer (polylactic acid) contained in the container were taken out.
  • the polymer was measured for physical properties (Mn, Mw/Mn, polymer conversion rate), which are shown in Table 1-1.
  • Example 1-1 The procedure of Example 1-1 was repeated, except that the amount of the initiator was changed as shown in the columns of Examples 1-2 to 1-4 in Table 1-1, to thereby obtain polymers.
  • Example 1-1 The procedure of Example 1-1 was repeated, except that the reaction temperature was changed as shown in the columns of Examples 1-5 to 1-7 in Table 1-1, to thereby obtain polymers.
  • Example 1-1 The procedure of Example 1-1 was repeated, except that the reaction pressure and the reaction temperature were changed as shown in the columns of Examples 1-8 to 1-10 and Comparative Examples 1-1 to 1-3 in Table 1-2, to thereby obtain polymers.
  • Example 1-1 The procedure of Example 1-1 was repeated, except that the organic catalyst used was changed to 4-dimethylaminopyridine (DMAP) and that the reaction pressure and the reaction temperature were changed as shown in the columns of Examples 1-11 to 1-16 in Table 1-3, to thereby obtain polymers.
  • DMAP 4-dimethylaminopyridine
  • Example 1-1 The procedure of Example 1-1 was repeated, except that the initiator used was changed to ethanol in Example 1-17, to 2-propanol in Example 1-18, to t-butanol in Example 1-19 or to trifluoroethanol in Example 1-20, to thereby obtain a polymer.
  • the obtained polymer was measured for physical properties, which are shown in Table 1-4.
  • Example 1-1 The procedure of Example 1-1 was repeated, except that the organic catalyst used was changed to 1,4-diazabicyclo-[2.2.2]octane (DABCO) in Example 1-21, to 1,8-diazabicyclo[5.4.0]undec-7-ene (DBU) in Example 1-22 or to 1,3-di-tert-butylimidazol-2-yldene (ITBU) in Example 1-23, to thereby obtain a polymer. Also, the procedure of Example 1-1 was repeated, except that no organic catalyst was used and that the reaction temperature was changed to 80° C., to thereby obtain a polymer of Comparative Example 1-4.
  • DABCO 1,4-diazabicyclo-[2.2.2]octane
  • DBU 1,8-diazabicyclo[5.4.0]undec-7-ene
  • ITBU 1,3-di-tert-butylimidazol-2-yldene
  • Example 1-1 The procedure of Example 1-1 was repeated, except that the ring-opening polymerizable monomer used was changed to E-caprolactone and that the organic catalyst used was changed to diphenylguanidine (DPG), to thereby obtain a polymer of Example 1-24. Also, the procedure of Example 1-1 was repeated, except that the ring-opening polymerizable monomer used was changed to ⁇ -caprolactone and that the organic catalyst used was changed to 1,5,7-triazabicyclo[4.4.0]dec-5-ene (TBD), to thereby obtain a polymer of Example 1-25.
  • DPG diphenylguanidine
  • Example 1-1 was repeated, except that the ring-opening polymerizable monomer used was changed to ethylene carbonate and that the organic catalyst used was changed to 1,8-diazabicyclo[5.4.0]undec-7-ene (DBU), to thereby obtain a polymer of Example 1-26.
  • DBU 1,8-diazabicyclo[5.4.0]undec-7-ene
  • the obtained polymers were measured for physical properties, which are shown in Table 1-5.
  • a pressure-resistant container was charged with a lactide of an L-lactic acid (90 parts by mass), a lactide of a D-lactic acid (10 parts by mass), lauryl alcohol (serving as an initiator) in an amount of 3.00 mol % relative to 100 mol % of the monomer, and 4-pyrrolidinopyridine (PPY) (3.3 parts by mass) and then heated to 60° C.
  • a lactide of an L-lactic acid 90 parts by mass
  • a lactide of a D-lactic acid 10 parts by mass
  • lauryl alcohol serving as an initiator
  • PPY 4-pyrrolidinopyridine
  • isophorone diisocyanate chain extender
  • isophorone diisocyanate chain extender
  • This container was charged with supercritical carbon dioxide (60° C., 10 MPa), and then the resultant mixture was added dropwise to the pressure-resistant container by its own weight after these containers had been adjusted so as to be equal in pressure, followed by reaction at 60° C. for 10 hours.
  • a pressure pump and a back pressure valve were used to adjust the flow rate at the outlet of the back pressure valve to 5.0 L/min.
  • supercritical carbon dioxide was allowed to flow for 30 min, and PPY and the residual monomer (lactide) were removed.
  • reaction system was gradually returned to normal temperature and normal pressure. Three hours after, a polymer (polylactic acid) contained in the container were taken out.
  • the polymer was measured for physical properties (Mn, Mw/Mn, polymer conversion rate), which are shown in Table 1-6.
  • Example 1-27 The procedure of Example 1-27 was repeated, except that the chain extender was changed to hexamethylene diisocyanate in Example 1-28, to tolylene diisocyanate in Example 1-29, or to neopentyl glycol diglycidyl ether in Example 1-30, to thereby obtain polymers of Examples 1-28 to 1-30.
  • the obtained polymers were measured for physical properties (Mn, Mw/Mn, polymer conversion rate), which are shown in Table 1-6.
  • the temperature was decreased to 0° C., and the pressure was decreased to normal pressure using a back pressure valve, to thereby obtain surfactant 2 having the following Structural Formula.
  • the number average molecular weight (Mn) thereof was found to be 2,500.
  • q is an integer of 1 or greater indicating the number of repeating units.
  • Polyacrylic acid 5,000 (product of Wako Pure Chemical Industries, Ltd.) (36.1 parts by mass), chloroform (product of Wako Pure Chemical Industries, Ltd., 1,480 parts by mass) and 1,1′-carbonylbis-1H-imidazole (128 parts by mass) were added to a 6 mL-vial container, followed by stirring at room temperature for 10 min.
  • polyethylene glycol product of Wako Pure Chemical Industries, Ltd., molecular weight: 200
  • 500 parts by mass was added thereto, followed by stirring at room temperature for 12 hours.
  • chloroform was added thereto, followed by washing with water.
  • each of r and p is an integer of 1 or greater indicating the number of repeating units.
  • Silicone oil carboxy-modified at its side chain (product of Shin-Etsu Silicones Co., KF-8012, particle diameter: 4,500) (12 parts by mass), chloroform (product of Wako Pure Chemical Industries, Ltd.) (33.3 parts by mass), 1,1′-carbonylbis-1H-imidazole (product of Wako Pure Chemical Industries, Ltd., molecular weight: 162, 0.65 parts by mass) and polyethylene glycol (product of Wako Pure Chemical Industries, Ltd., molecular weight: 200, 0.80 parts by mass) were added to a 50 mL-egg plant flask, followed by stirring at room temperature for 12 hours.
  • chloroform product of Wako Pure Chemical Industries, Ltd.
  • 1,1′-carbonylbis-1H-imidazole product of Wako Pure Chemical Industries, Ltd., molecular weight: 162, 0.65 parts by mass
  • polyethylene glycol product of Wako Pure Chemical Industries, Ltd., molecular weight: 200, 0.80 parts by mass
  • Silicone oil amino-modified at its side chain and methoxy-modified at both ends (product of Shin-Etsu Silicones Co., KF-857, molecular weight: 790) (7.9 parts by mass), dichloromethane (product of Tokyo Chemical Industry Co., Ltd.) (66.6 parts by mass) and phenyl isocyanate (product of KANTO KAGAKU) (3.6 parts by mass) were added to a 300 mL-egg plant flask, followed by stirring at room temperature for 24 hours. Thereafter, hexane was added thereto, followed by washing with distilled water. The resultant reaction mixture was dried with sodium sulfate anhydrate and filtrated with cotton and silica gel, and the solvent was evaporated under reduced pressure, to thereby obtain surfactant 9 having the following Structural Formula (yield: 80%).
  • a micro tube was charged with L-lactide (882.4 parts by mass), 4-dimethylaminopyridine (DMAP) (48.9 parts by mass), surfactant 1 (49.7 parts by mass) and anhydrous ethanol (9.2 parts by mass).
  • the micro tube was placed in a pressure-resistant container and heated to 60° C. Then, supercritical carbon dioxide (60° C., 8 MPa) was charged thereinto, followed by reaction at 60° C. for 2 hours.
  • the pressure pump and the back pressure valve were used to adjust the flow rate at the outlet of the back pressure valve to 5.0 L/min. Then, supercritical carbon dioxide was allowed to flow for 30 min. After the organic catalyst and the residual monomers had been removed, the reaction system was gradually returned to normal temperature and normal pressure. Three hours after, polymer particles 1 contained in the container were taken out.
  • FIG. 3 is an electron microscope image showing the aggregation state of polymer particles 1, which is obtained in the following manner.
  • FIG. 4 is an electron microscope image of each of polymer particles 1.
  • FIG. 5 is an image obtained by photographing polymer particle 1 with a digital camera. As is clear from these images, the produced polymer particles were found to have a size of about 40 ⁇ m or less.
  • polymer particles 1 were measured for physical properties (Mn, Mw/Mn, polymer conversion rate), which are shown in Table 2-1.
  • the polymer was observed with a scanning electron microscope or SEM under the following conditions.
  • Example 2-1 The procedure of Example 2-1 was repeated, except that the catalyst used, the type and amount of the surfactant, the type of the monomer and the reaction conditions are changed as shown in the respective columns of Examples 2-2 to 2-24 in Tables 2-1 to 2-4, to thereby obtain polymer particles 2-2 to 2-24.
  • surfactants 5 to 8 have structures expressed by the following General Formulas.
  • n is an integer of 1 or greater indicating the number of repeating units.
  • n is an integer of 1 or greater indicating the number of repeating units.
  • each of m and n is an integer of 1 or greater indicating the number of repeating units.
  • each of m and n is an integer of 1 or greater indicating the number of repeating units.
  • Example 1 From electron microscope images of the polymer particles photographed in the same manner as in Example 1, the polymer particles were found to be somewhat varied in size but have a similar size to those of Example 1.
  • these polymer particles were measured for physical properties (Mn, Mw/Mn, polymer conversion rate), which are shown in Tables 2-1 to 2-4.
  • Example 2-1 The procedure of Example 2-1 was repeated, except that no surfactant was used, and the type and amount of the monomer were changed as shown in the columns of Comparative Examples 2-1 and 2-2 in Table 2-4 for producing polymer particles. As a result, only aggregated polymer could be obtained.
  • FIG. 6 is a photograph of the aggregated polymer of Comparative Example 2-1, which was taken with a digital camera.

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